Open Top Cage Receptacle Assembly

The present disclosure is generally directed toward connector assemblies associated with optical, active, and high-powered cables used in conjunction with switch systems, modules, and other optical and electrical components. In particular, cages, shells, and housings of connector and receptacle assemblies are described which utilize heat dissipation units and elements that are configured to increase thermal performance.

Datacenter switch systems and associated modules may include connections between other switch systems, servers, racks, and devices. Such connections may be made using cables, transceivers, cage receptacles, and connector assemblies, which may include a shell or housing configured to protect these connections from damage. Often, these cage receptacles can generate heat during operation, which can result in the failure of system components.

Apparatuses and associated methods of manufacturing are described that provide a cage receptacle assembly configured to receive a cable connector. The cage receptacle assembly includes a cage body defining a first end and a second end. The cage body includes a top cage member attached to a bottom cage member via two side portions of the top cage member, and the top cage member defines an opening. The cage body can be constructed from a single piece of material (e.g., it may be integrally-formed) or may be constructed of multiple pieces that are attached together by at least one of welding, gluing, fastening, or the like. The cage receptacle assembly defines a heat dissipation unit disposed within the opening of the top cage member, wherein the heat dissipation unit directly contacts a port back shell. The heat dissipation unit may include one or more heat dissipation elements allowing heat to be transferred from the cable connector to an external environment of the cage receptacle assembly. The opening in the top cage member is enlarged for more efficient heat dissipation. For example, a pedestal in previous cage assemblies is omitted to permit direct contact between a connector and a heat dissipation unit.

The present disclosure relates in general to optical, active, and high-powered cables and associated connector assemblies used in conjunction with datacenter switch systems, modules, and other optical and electrical components. In particular, cages, shells, and housings of connector and receptacle assemblies are described which utilize heat dissipation units and elements that are configured to increase the thermal performance of connector assemblies.

Datacenter switch systems and associated modules may generally include connections between other switch systems, servers, racks, and devices. Such connections may be made using cables, transceivers, cage receptacles, and connector assemblies, which may include a shell or housing configured to protect these connections from damage. Often, these cage receptacles can generate heat during operation, which can result in the failure of system components.

Accordingly, the apparatuses and methods of manufacturing described herein provide a cage receptacle assembly configured to receive a cable connector. In some embodiments, the cage receptacle assembly may include a cage body defining a first end and a second end. The cage body may include a top cage member defined by a top portion and two side portions and a bottom cage member attached to the top cage member via the two side portions of the top cage member. The top cage member may define an opening. In embodiments, the cage body may be formed as a single part with a top, sides, and bottom. The cage body may define a receiving space configured to at least partially receive a cable connector therein via the first end such that a top surface of the cable connector is disposed proximate the top cage member and a bottom surface of the cable connector is disposed proximate the bottom cage member. The second end of the cage body may be configured to be received by a datacenter rack for enabling signals to pass between the cable connector that is at least partially received therein and the datacenter rack. A heat dissipation unit may be disposed within the opening in the top cage member. A second heat dissipation unit may be disposed within the opening in the bottom cage member Each heat dissipation unit may further include one or more heat dissipation elements (e.g., fins) configured to allow heat to be transferred from the cable connector that is at least partially received within the receiving space to an external environment of the cage receptacle assembly.

In embodiments, each heat dissipation unit may include one or more heat dissipation elements. The one or more heat dissipation elements may include fins or other structures to increase an overall surface area of the one or more heat dissipation elements.

In embodiments, the cage receptacle assembly may be attached to a printed circuit board assembly disposed adjacent to the bottom cage member. The printed circuit board assembly may also define a corresponding opening configured to substantially align with the opening defined by the bottom cage member. In embodiments, the bottom portion of the bottom cage member may define an opening configured to receive one or more additional heat dissipation units. For example, the heat dissipation unit is disposed within the opening defined by the bottom cage member may also be configured to be disposed within the corresponding opening of the printed circuit board assembly.

In other cases, in an instance in which the cable connector is at least partially received or fully received within the cage body, the cage receptacle assembly may further be configured such that the heat dissipation unit directly contacts the cable connector.

In embodiments, the bottom cage member may be integral to the top cage member.

In embodiments, the cage body is formed as a single piece. In other embodiments, the cage body is formed of two or more pieces that are connected or joined together.

In some further embodiments, the one or more heat dissipation elements may include fins. These fins may also be disposed substantially perpendicular with respect to the bottom cage member.

In some cases, the heat dissipation unit may include a first set of heat dissipation elements having a first height, and a second set of heat dissipation elements having a second height, wherein the second height is different than the first height. In such a case, the second height of the second set of heat dissipation elements may be greater than the first height of the first set of heat dissipation elements such that a portion of the second set extends through a plane defined by an inner surface of the heat dissipation unit corresponding to a location of the first set of heat dissipation elements.

In any of the above embodiments, the cable connector may be a quad small form factor pluggable cable connector.

In other embodiments, a method of manufacturing a cage receptacle assembly configured to receive a cable connector is provided. The method may include providing a top cage member defined by a top portion and two side portions and providing a bottom cage member. The method may include attaching the bottom cage member to the top cage member via the two side portions of the top cage member to form a cage body defining a first end and a second end. The cage body may define a receiving space configured to at least partially receive a cable connector therein via the first end such that a top surface of the cable connector is disposed proximate the top cage member and a bottom surface of the cable connector is disposed proximate the bottom cage member, and the second end may be configured to be received by a datacenter rack for enabling signals to pass between the cable connector that is at least partially received therein and the datacenter rack. The method may also include disposing a heat dissipation unit within an opening in the top and/or bottom cage member to allow heat to be transferred from the cable connector that is at least partially received within the receiving space to an external environment of the cage receptacle assembly.

In embodiments, the method may also include disposing a printed circuit board assembly adjacent the bottom cage member, and the printed circuit board assembly may define a corresponding opening configured to substantially align with the opening defined by the bottom cage member. In such an embodiment, the printed circuit board assembly adjacent the bottom cage member may be configured such the heat dissipation unit disposed within the opening defined by the bottom cage member is disposed within the corresponding opening of the printed circuit board assembly.

In other cases, in an instance in which the cable connector is at least partially received within the cage body, the cage receptacle assembly may be further configured such that the heat dissipation unit directly contacts the cable connector.

In embodiments, a cage receptacle assembly may be provided that includes a cage body defining a first end and a second end. The cage body may include a top cage member defined by a top portion and two side portions. The cage body may define a receiving space configured to at least partially receive a cable connector therein via the first end such that a top surface of the cable connector is disposed proximate the top cage member and a bottom surface of the cable connector is disposed proximate the bottom cage member, and the second end may be configured to be received by a datacenter rack for enabling signals to pass between the cable connector that is at least partially received therein and the datacenter rack.

Additional features and advantages are described herein and will be apparent from the following Description and the figures.

Like reference numbers and designations in the various drawings indicate like elements.

The ensuing description provides embodiments only, and is not intended to limit the scope, applicability, or configuration of the claims. Rather, the ensuing description will provide those skilled in the art with an enabling description for implementing the described embodiments. It is understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the appended claims.

As used herein, the phrases “at least one,” “one or more,” “or,” and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C,” “A, B, and/or C,” and “A, B, or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

Various aspects of the present disclosure will be described herein with reference to drawings that are schematic illustrations of idealized configurations.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and this disclosure.

As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The term “and/or” includes any and all combinations of one or more of the associated listed items.

Embodiments of the present disclosure will now be described more fully hereinafter with reference to the accompanying figures. It should be appreciated that the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

Like numbers refer to like elements throughout. As used herein, terms such as “front,” “rear,” “top,” etc. are used in the examples provided below to describe the position of certain components or portions of components in an installed and operational configuration. As used herein, the term “module” encompasses hardware, software and/or firmware configured to perform one or more particular functions, including but not limited to conversion between electrical and optical signals and transmission of the same. As would be evident to one of ordinary skill in the art in light of the present disclosure, the term “substantially” indicates that the referenced element or associated description is accurate to within applicable engineering tolerances.

As discussed herein, embodiments will be described with reference to a pluggable connector. It should be appreciated that embodiments of the present disclosure contemplate the use of any suitable pluggable connector. Non-limiting examples of suitable pluggable connectors that may be used in accordance with at least some embodiments include an octal small form factor pluggable (OSFP) connector or a quad small form factor pluggable (QSFP) connector. The embodiments of the present invention may be equally applicable for use with other types of connectors, which may include, without limitation, small form pluggable (SFP), C-form factor pluggable (CFP), and the like. Moreover, the embodiments of the present invention may also be used with any cable (e.g., passive copper cable (PCC), active copper cable (ACC), or the like) or interconnect utilized by datacenter racks and associated interconnect modules (e.g., an active optical module (AOM), QSFP transceiver module, OSFP transceiver module, or the like).

Additionally, as discussed herein, the embodiments are described with reference to a vertical-cavity surface-emitting laser (VCSEL) as an element of a transceiver system; however, embodiments of the present disclosure may be equally applicable for use with any transceiver system and/or element. Still further, as discussed herein, the example embodiment is described with reference to an interconnect module configured to receive a cage receptacle assembly to allow signals to pass between a cable connector and the interconnect module. The present disclosure, however, contemplates that a network interface, a high-capacity adapter, or any other applicable networking interface may equally be used instead or in conjunction with the interconnect module to receive the cage receptacle.

Extensive growth in global internet traffic due to increasing demands for high-definition video and high-speed broadband penetration has required new hardware that allows for higher data transmission rates in datacenters. These developments have resulted in the use of optical fibers offering enhanced capacity (e.g., greater bandwidth) over distance, increased bandwidth density, greater security and flexibility, and lower costs as compared to conventionally-used copper cables. A datacenter rack, or cabinet that is designed to house servers, networking devices, modules, and other datacenter computing equipment and used in conjunction with optical fibers, is depicted in.

Accordingly, various different types of cable connectors also exist for enabling transmission of signals (optical and/or electrical) between interconnect modules and other equipment in a datacenter. For example, QSFP connectors and cables, as well as other forms of connectors such as OSFP connectors, SFP connectors, CFP connectors, and OSFP transceivers provide high-speed information operations interface interconnects. Regardless of the type of cable connector, these transceivers may interface a switch system board, such as a motherboard in a switch system, to a fiber optic or copper networking cable, such as by making connections between interconnect modulesas shown in.

With continued reference to, for example, an interconnect module, which may house an application-specific integrated circuit (ASIC) as well as other internal components (not visible), is typically incorporated into a datacenter network via connections to other switch systems, servers, racks, and network components. Interconnect modulemay, for example, interact with other components of the datacenter via external optical cablesand possible transceiver systems housed in the end of an optical cable. These optical cablesand transceivers may allow connections between an interconnect module and the other components of the datacenter network via cage receptacle assemblies.

The interconnect modulesmay be configured to be received by the datacenter rackand may be configured to allow for the conversion between optical signals and electrical signals. For example, optical cablesmay carry optical signals as inputs to the interconnect module. The optical signals may be converted to electrical signals via an opto-electronic transceiver assembly, which may form part of the optical cablein cases in which the optical cableis an Active Optical Cable (AOC), such as a cable that includes a QSFP connector that is received by a port of an interconnect module. In other cases, the optical cablemay be passive, and the switch modulemay include opto-electronic components that convert between optical signals and electrical signals. The electrical signals may then be processed by the interconnect moduleand/or routed to other computing devices, such as servers and devices on other racks or at other datacenters via other components and cables (not shown). In addition, electrical signals received from other networking devices (e.g., from other datacenters, racks, etc.) may be processed by the interconnect moduleand then converted into corresponding optical signals to be transmitted via the optical cables, going the opposite direction.

The transmission of data as electrical signals and the conversion between optical signals and electrical signals (e.g., via an AOCand associated transceiver system or AOM) often results in the generation of heat by the components of the datacenter rack. As would be understood by one of ordinary skill in the art in light of the present disclosure, higher temperatures associated with such heat emissions can correspond to the increased likelihood of failure of electrical components and/or changes in the electrical and/or optical operating parameters of the components resulting in interference with the corresponding electrical and/or optical signals. Additionally, localization or concentration of higher temperatures in electrical components (e.g., the bottom surface of the AOC, AOM, QSFP, or OSFP cable connector) can result in a further increase in the likelihood of failure of electrical components located near the area of concentration.

Accordingly, embodiments of the invention described herein provide a cage receptacle assembly that is configured to provide improved thermal performance by enlarging the contact area between a connector and a heat dissipation unit(s) to more efficiently distribute heat and/or to more effectively dissipate the heat to the surrounding environment to maintain lower temperatures in the components.

illustrate different views of an example of a cage assembly. In particular,illustrates an example of a cage assemblywith a first heat dissipation unitA shown whereasillustrates the cage assemblywith the first heat dissipation unitA removed, thereby providing a view of the underlying components.further illustrates the spring(s)that may be used to secure the first heat dissipation unitA to the cage body. The cage assemblyis also shown to include a second heat dissipation unitB, which is provided on an opposite side of the cage bodyfrom the first heat dissipation unitA. The cage bodymay be mounted to a printed circuit board (PCB), which may include other optical and/or electrical components connected thereto (not shown).illustrates an example cable connectorthat may be used to interface and/or interconnect with the cage receptacle assembly.

The cage assemblyincludes a cage body. The cage bodyof the cage receptacle assemblymay be defined by a top cage memberthat defines a top portionand two side portionsthat extend between the top portionof the top cage memberto a bottom cage member. The top cage membermay be configured to attach to the bottom cage memberto form the cage body. The cage bodyof the cage receptacle assemblymay be configured to at least partially receive a cable connector(e.g., a QSFP or OSFP cable and/or connector) such that a top surfaceof the cable connectoris disposed proximate the top cage memberand a bottom surfaceof the cable connectoris disposed proximate the bottom cage member.

The cage receptacle assemblymay also define a first endand a second endopposite the first end, where the first endis configured to receive the cable connector. For example, the first endof the cage receptacle assemblymay be defined such that at least a portion of the cable connectormay be inserted into the cage receptacle assembly, or otherwise brought into engagement or contact with an inner surface of cage receptacle assemblyvia the first end. The first endmay be configured to receive a cable connectorof any suitable dimension or of any type (e.g., AOC, Ethernet, Direct Attach Copper, etc.) such that the top cage memberis located proximate the top surfaceof the cable connectorand the bottom cage memberis located proximate the bottom surfaceof the cable connector.

By way of example, the first endmay be configured to receive a cable connectorcorresponding to a QSFP cable connector, such that the QSFP cable connector is secured to the cage receptacle assemblyby engaging at least a part of the inner surface cage receptacle assemblyvia the first end.

In a similar fashion and as will be described with reference to, embodiments of the present disclosure provide a cage bodyhaving an opening at its first endthat is configured to receive a cable connector. As will be discussed in further detail herein, the opening in the first enddefined by the cage bodyof the cage receptacle assemblymay be configured such that a cable connectorextends through the cage bodyof the cage receptacle assembly. Specifically, the cable connectormay be configured (e.g., sized and shaped) such that upon engagement of a second endof the cage receptacle assemblywith the module, the cable connectormay also engage the module such that electrical and/or optical signals may be transmitted between the cableand module.

The cage receptacle assemblymay further define a second endopposite the first end, where the second endis configured to be received by an interconnect module for enabling signals to pass between the cable connector and a module. The cage receptacle assemblymay be configured to engage, or be secured to, a module (e.g., interconnect modulein). The cage receptacle assemblymay be configured such that the second enddefines at least one extension capable of being received by a datacenter interconnect module(e.g., male to female connection).

By way of a more particular example, a QSFP cable connector may be received by the cage receptacle assemblysuch that at least a portion of the QSFP cable connector is supported and/or surrounded by the cage bodyof the cage receptacle assembly. The active end of the QSFP cable connector (e.g., the end configured to engage a module and allow electrical communication therethrough) may be positioned such that when the cage receptacle assemblyengages the module, the active end of the QSFP cable connector engages a corresponding port of the system to allow signals (e.g., electrical signals, optical signals, or the like) to travel between the QSFP cable connector and the interconnect module.

, illustrate a PCBon which a cage assembly (e.g., cage bodyin) may be disposed. In, the cage assembly is covered by a first heat dissipation unitA. The PCBmay be attached or otherwise secured to a cage body. In some embodiments, the cage bodymay comprise one or more legs that extend through one or more holes in the PCBto support an accurate positioning of the cage bodyrelative to the PCB. As would be understood by one of ordinary skill in the art in light of the present disclosure, the PCBmay include various optical and/or electrical components (e.g., passive circuit components, active circuit components, Integrated Circuit (IC) chips, ASICs, microprocessors, etc.). In some embodiments, the PCBmay include one or more transducers (e.g., vertical-cavity surface-emitting lasers (“VCSELs”)) configured to convert electrical signals into optical signals, and/or one or more photodiodes configured to convert optical signals into electrical signals.

As shown in the exploded view of, the PCBmay define an openingconfigured to substantially align with an openingB of the bottom cage memberillustrated in. A second heat dissipation unitB, described in greater detail below, may be received by the openingB and may be further configured to be disposed within the corresponding openingof the PCBwhen the second heat dissipation unitB is disposed within the openingB in the bottom of the cage body. A bottom view of the PCBis illustrated inhelping to illustrate the second heat dissipation unitB positioned within the openingB of the cage bodyand the openingof the PCB.

It should be appreciated that the cage bodymay be constructed of metal or a similar type of material. As some non-limiting examples, the cage bodymay be formed of a sheet metal that is punched and folded to an appropriate form. Alternatively or additionally, the cage bodymay be cast, milled, printed, or formed using any other suitable fabrication method.

As illustrated in the exploded views of, in embodiments in which a PCBis disposed adjacent the bottom of the cage assembly, the second heat dissipation unitB may also be received by the corresponding openingof the PCB. In such an embodiment, the second heat dissipation unitB may be dimensioned such that direct contact between the second heat dissipation unitB and the PCBis precluded. Further, the dimensioning of the corresponding openingmay be such that the second heat dissipation unitB is fully received by the openingB of the bottom cage member. Said another way, the openingmay be dimensioned such that the PCBdoes not inhibit contact between the second heat dissipation unitB and a cable connectorat least partially received by the cage receptacle assembly. For example, a width and length of the openingmay be configured to provide maximum contact between the heat dissipation unitB and the bottom side of cable connector received by the cage receptacle assembly.

The first heat dissipation unitA and/or second heat dissipation unitB may be configured to facilitate the transfer of heat from a cable connectorthat is at least partially received within the cage body. One or both heat dissipation unitsA,B may be secured to the PCBvia one or more springs. Although the configuration of the cage receptacle assemblyis shown to include three springs, it should be appreciated that a greater or fewer number of springsmay be used to couple the heat dissipation unit(s)A,B to the cage bodyas part of completing construction of the cage receptacle assembly. An advantage of using springsis that the heat dissipation unit(s)A,B may be releasably coupled to the cage body, thereby allowing for an interchanging of components and/or modular replacement of components. The first heat dissipation unitA may be formed of a single piece of material (e.g., may be cast, molded, or otherwise formed from a single material). Alternatively, the first heat dissipation unitA may be formed of two or more pieces of material that are connected to one another (e.g., by welding, gluing, fastening, etc.). For instance, a top portion of the first heat dissipation unitA may correspond to a first piece of material that is connected to two discrete side portions to form the U-shaped configuration shown in. The first heat dissipation unitA and/or second heat dissipation unitB may be constructed from any suitable material that is capable of transferring thermal energy. Non-limiting examples of materials that may be used to form the heat dissipation unit(s)A,B include metal materials (e.g., gold, silver, Aluminum, copper, etc.), ceramic materials, graphite, metal alloys, silicon carbide, etc.

As can be seen in, the first heat dissipation unitA may, for example, define heat dissipation elements(e.g., fins), which extend substantially perpendicularly outwardly. The heat dissipation elementsmay, in some embodiments, define a plurality of fins having rectangular cross-sections. While the description herein refers to the heat dissipation elementsconfigured as pins or fins, the present disclosure contemplates that any extension having any cross-sectional shape may be used as the heat dissipation elements. Furthermore, the present disclosure contemplates that any number of heat dissipation elements may be defined by the heat dissipation unitsA-B and may be positioned at any angle and/or arrangement. The heat dissipation elementsmay be configured to extend the overall surface area of the first heat dissipation unitA. As shown in, the second heat dissipation unitB may also include fins or similar structures to enhance the overall surface area of the second heat dissipation unitB.

The one or more heat dissipation elements(e.g., the pluralities of fins) may facilitate the transfer of heat from the cable connectorto an external environment of the cage receptacle assemblyby increasing the convective cooling experienced by the cage receptacle×the rate of heat transfer to an external environmental via the increased surface area provided by the heat dissipation elementsin the portion of the cage receptacle assemblycontacting the external environment. In other words, by utilizing a heat dissipation unitsA-B including heat dissipation elements(e.g., a plurality of fins), the cage receptacle assemblymay increase its surface area for heat dissipation such that a larger area is in contact with the air of its external environment (e.g., the air from the environment that is contained and/or flowing through the one or more heat dissipation elements). As such, air traveling between and around the one or more heat dissipation elementsis able to receive more heat transferred from the body of the cage receptacle assemblythan it would have otherwise if contacting a single, flat surface. As a result, the temperature of the heat dissipation unitsA-B (e.g., at the ends of the pluralities of fins) should remain lower than the temperature of the rest of the cage bodyof the cage receptacle assembly(e.g., the combined top cage member and bottom cage member) to provide a larger temperature gradient between these surfaces, thereby serving as a heat sink. The resultant temperature gradient also facilitates transfer of heat from the cage receptacle assemblyand optical connector cable to the external environment.

As would be understood by one of ordinary skill in the art in light of the present disclosure, with reference to, the one or more heat dissipation elements(e.g., the pluralities of fins) may improve heat dissipation from the cage receptacle assemblyby providing contact between a contact surface of the heat dissipation unitsA-B and the cable connector that is at least partially received within the cage receptacle assembly. With reference to, the openingsA-B may be configured such that each respective heat dissipation unit(s)A,B contacts a surface of a cable connector when the connector is at least partially received by the cage receptacle assembly. In particular, as shown in, a contact portionof the first heat dissipation unitA may be configured to directly contact the cable connectorwhen the cable connectoris received in the cage receptacle assembly(e.g., inserted into the cage body). The contact portionmay protrude relative to the other bottom-facing surfaces of the first heat dissipation unitA. In some embodiments, the contact portionmay comprise a conductive material (e.g., a thermal interface material (TIM) such as a phase-change material or the like).